U.S. patent number 5,310,430 [Application Number 07/708,510] was granted by the patent office on 1994-05-10 for process of dispensing a solid cast block of water soluble detergent.
This patent grant is currently assigned to Ecolab Inc.. Invention is credited to John E. McCall, Jr..
United States Patent |
5,310,430 |
McCall, Jr. |
May 10, 1994 |
**Please see images for:
( Certificate of Correction ) ** |
Process of dispensing a solid cast block of water soluble
detergent
Abstract
A solid cast block of water soluble detergent is dispensed by
obtaining a solid detergent article of at least twenty liters cast
onto a longitudinally extending structural core and placing the
article within the spray chamber of a dispenser such that the
article is supported on the structural core. The detergent article
is then rotated upon the structural core while dissolving solvent
is sprayed upon the rotating article. The resulting detergent
solution is dispensed to an end use point.
Inventors: |
McCall, Jr.; John E. (West
Saint Paul, MN) |
Assignee: |
Ecolab Inc. (St. Paul,
MN)
|
Family
ID: |
24846065 |
Appl.
No.: |
07/708,510 |
Filed: |
May 31, 1991 |
Current U.S.
Class: |
134/33; 134/93;
137/268; 366/137; 510/224; 510/225; 510/447 |
Current CPC
Class: |
A47L
15/4436 (20130101); C11D 17/0052 (20130101); B01F
1/0027 (20130101); Y10T 137/4891 (20150401) |
Current International
Class: |
A47L
15/44 (20060101); B01F 1/00 (20060101); C11D
17/00 (20060101); B08B 007/00 (); B08B 003/04 ();
C11D 017/00 () |
Field of
Search: |
;422/263,264,269,271,281
;134/93,33 ;252/90,92,134,DIG.16,174 ;366/137,167 ;137/268 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
0242966 |
|
Oct 1987 |
|
EP |
|
847650 |
|
Aug 1952 |
|
DE |
|
2084500 |
|
Mar 1990 |
|
JP |
|
WO89/11753 |
|
Nov 1989 |
|
WO |
|
687075 |
|
Feb 1953 |
|
GB |
|
Other References
Abstract of Japanese Patent Publication 62-36500..
|
Primary Examiner: Lewis; Michael
Assistant Examiner: Kalinchak; Stephen G.
Attorney, Agent or Firm: Merchant, Gould, Smith, Edell,
Welter & Schmidt
Claims
I claim:
1. A method of dispensing a solid cast block of water-soluble
detergent composition, comprising the steps of:
obtaining an article of commerce comprising at least twenty liters
of a solid detergent composition cast onto a longitudinally
extending structural core wherein the solid cast detergent
composition defines an exposed surface area;
obtaining a spray-type dispenser having a spray chamber and a spray
nozzle directed into the spray chamber;
placing the article of commerce within the spray chamber of the
dispenser such that the solid detergent composition is suspended
within the spray chamber upon the structural core which is in
contact with the dispenser;
rotating the article of commerce within the spray chamber about the
structural core;
spraying a dissolving solvent through the spray nozzle and into
contact with the exposed surface area of the rotating detergent
composition so as to dissolve a portion of the detergent
composition and form a use solution of the detergent composition;
and
directing the use solution out of the dispenser and to an end use
point substantially immediately after formation of the use
solution.
2. The method of claim 1 wherein the solid cast detergent
composition has a plurality of longitudinally extending passageways
projecting completely through the solid cast block of detergent
composition.
3. The process of claim 1 wherein the article of commerce includes
at least 50 liters of solid cast detergent composition.
4. The process of claim 1 wherein the article of commerce includes
at least 100 liters of solid cast detergent composition.
5. The process of claim 1 wherein the article of commerce includes
at least 500 liters of solid cast detergent composition.
6. The process of claim 1 wherein the article of commerce is
rotated by means of a motorized gear linkage in communication with
the structural core.
7. The process of claim 1 wherein the dissolving solvent is water.
Description
FIELD OF THE INVENTION
Broadly, the invention relates to the casting of molten detergent
compositions. Specifically, the invention relates to the casting of
oversized blocks of molten detergent compositions.
BACKGROUND
The advent of solid cast detergent compositions has revolutionized
the manner in which detergents are used and dispensed by those
commercial and institutional entities which routinely use large
quantities of cleaning solution. Prior to the advent of solid cast
detergents, detergents were available in liquid, granular or pellet
form. The solid cast form, such as those disclosed in Re. U.S. Pat.
No. 32,763, Re. U.S. Pat. No. 32,818, U.S. Pat. Nos. 4,680,134 and
4,595,520, offered numerous unique advantages and quickly replaced
a major portion of the conventional liquid, granular and pellet
forms in the commercial and institutional markets.
The unique advantages offered by the solid cast forms of detergent
include improved handling resulting in enhanced safety, elimination
of component segregation during transportation and storage,
increased concentration of active ingredients within the
composition, and numerous others.
One method of manufacturing solid cast detergent compositions
involves the steps of forming a homogenous melt of the various
components, casting the molten melt into a mold, and solidifying
the melt by cooling. For example, Fernholz et al., Reissue U.S.
Pat. No. 32,763, describes a method of manufacturing a solid cast
detergent composition which involves the steps of (i) forming an
aqueous solution or dispersion of two hydratable chemicals, such as
sodium hydroxide and sodium tripolyphosphate, (ii) heating the
solution to a temperature of about 65.degree. to 85.degree. C. to
form a heated solution, (iii) increasing the concentration of
hydratable chemicals in the heated solution to produce a molten
mixture which is liquid at the elevated temperature but solid at
room temperature, and (iv) casting the molten mixture into molds
for cooling and solidification to room temperature.
One difficulty encountered in the manufacture of solid cast
detergent compositions by the molten process is the speed with
which complete solidification of the cast composition can be
achieved. It is understandably desirable to ensure that
substantially the entire volume of a cast block of detergent
composition is solid prior to effecting significant handling and/or
transportation thereof in order to reduce the possibility that any
remaining molten portion of the composition could be released and
result in property damage and/or personal injury.
Generally, cast molten detergent compositions tend to cool and
solidify from the exposed outer surfaces inward such that an outer
crust usually forms on the cast detergent composition while the
inner volume remains molten. This outer crust then tends to act as
a insulating barrier and slows cooling of the remaining molten
detergent composition. Because of this phenomena, it is generally
accepted that, even though certain commercial and institutional
users could benefit by using oversized blocks of solid cast
detergent composition, the size of solid cast blocks of detergent
composition formed by the molten process must be maintained below
about 20 liters in order to prevent unreasonable delay in effecting
complete solidification of the cast material.
In addition, the performance of solid cast detergent compositions
is generally enhanced by the inclusion of one or more heat
sensitive components such as tripolyphosphate detergent builders,
chlorine bleaches, and enzymes. These heat sensitive components can
be significantly degraded by extended exposure to the molten
detergent composition.
Another drawback encountered in the manufacture of solid cast
detergent compositions by the molten process is the need to employ
a returnable/disposable mold within which the detergent may be
cast, stored, transported, and dispensed. Disposable molds
contribute to the growing problem of solid waste control while
returnable molds are expensive to manufacture and cumbersome to
handle.
Accordingly, a substantial need exists for a simple and relatively
inexpensive process for producing oversized blocks of detergent
compositions by the molten process which minimizes cooling time,
reduces degradation of heat sensitive components, eliminates the
need for environmentally harmful disposable receptacles and
cumbersome returnable containers, and provides a generous exposed
surface area available for dissolution by a dissolving fluid during
dispensing.
SUMMARY OF THE INVENTION
I have discovered a simple and efficient process for casting large
blocks of molten detergent composition. The process employs a mold
with a plurality of longitudinally extending linear heat exchange
tubes dispersed within the casting chamber and includes the steps
of: pouring molten detergent composition into the casting chamber;
solidifying substantially the entire volume of molten detergent
composition within the casting chamber by removing heat from the
detergent composition through the heat exchange tubes; heating the
heat exchange tubes so as to melt an effective releasing amount of
the solidified detergent composition proximate the heat exchange
tubes and thereby permit the solid cast block of detergent to be
withdrawn from the casting chamber as a single unit; and removing
the solid cast block of detergent from the mold as a single
unit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of a casting system
useful in the process of the invention which includes molten
detergent composition within the casting chamber.
FIG. 2 is a top view of the mold of FIG. 1.
FIG. 3 is a cross-sectional side-view of the mold of FIG. 1.
FIG. 4 is an enlarged cross-sectional view of a portion of the mold
of FIG. 3.
FIG. 5 is a perspective view of one embodiment of a bulk block of a
solid cast detergent composition manufactured in accordance with
the invention.
FIG. 6 is perspective view of a spray-type dispenser useful in
dispensing the bulk block of solid cast detergent composition
manufactured in accordance with the invention including a block of
detergent composition.
FIG. 7 is a cross-sectional side-view of the dispenser of FIG.
6.
FIG. 8 is perspective view of a submersion-type dispenser useful in
dispensing the bulk block of solid cast detergent composition
manufactured in accordance with the invention including a block of
detergent composition.
FIG. 9 is a cross-sectional side-view of the submersion-type
dispenser of FIG. 8.
DETAILED DESCRIPTION OF THE INVENTION INCLUDING A BEST MODE
Mold
Nomenclature
001 casting system
10 mold
20 vessel
21 top of vessel
22 base of vessel
23 sidewall of vessel/exterior sidewall
25 horizontal dividing plate
26 central orifice through dividing plate
27 collar
28 O-ring seal
29 receptacle
30 central casting chamber
31 top of casting chamber
32 base of casting chamber/interior base plate
33 sidewall of casting chamber/interior sidewall
34 central orifice through interior base plate
35 baffle
36 top of baffle
37 bottom of baffle
40 annular encircling cavity
41 inner portion of encircling cavity
42 outer portion of encircling cavity
43 top of inner portion of encircling cavity
44 top of outer portion of encircling cavity
45 bottom of inner portion of encircling cavity
46 bottom of outer portion of encircling cavity
50 distribution chamber
51 periphery of distribution chamber
55 inlet
60 reservoir
65 outlet
70 heat exchange tubes
71 inner pipe
72 outer pipe
73 top of inner pipe
74 top of outer pipe
75 bottom of inner pipe
76 bottom of outer pipe
81 bore through inner pipe
82 annular cavity between inner and outer pipes
90 central shaft
91 first end of central shaft
92 second end of central shaft
100 heat exchange system
110 pump
120 heating unit
130 refrigeration unit
141 first length of conduit
142 second length of conduit
143 third length of conduit
144 fourth length of conduit
145 fifth length of conduit
151 junction point of second and third conduits
152 junction point of fourth and fifth
161 first valve
162 second valve
200 heat exchange fluid
300 detergent composition
300m molten body of detergent composition
300s solid cast block of detergent composition
CONSTRUCTION
The casting system 001 of the invention includes a mold 10 for
casting a detergent composition 300 and a heat exchange system 100
in fluid communication with the mold 10 for selectively
heating/cooling the detergent composition 300 cast within the mold
10. The casting system 001 provides for rapid solidification of an
oversized mass of molten detergent composition 300m cast within the
mold 10 and subsequent substantially effortless removal of the
solid cast block of detergent composition 300s from the mold
10.
The principal component of the mold 10 is a vessel 20 which defines
a cylindrical cavity (unnumbered) accessible through an open top
21. The cylindrical cavity (unnumbered) is separated by a
horizontal dividing plate 25 into upper (unnumbered) and lower
(unnumbered) chambers. The upper chamber (unnumbered) is
partitioned into a central cylindrical casting chamber 30, an
annular encircling cavity 40 surrounding the casting chamber 30,
and a cylindrical distribution chamber 50 immediately below the
casting chamber 30 and annular encircling cavity 40. The casting
chamber 30 is defined by an interior sidewall 33 and an interior
base plate 32. The annular encircling cavity 40 is defined by the
interior sidewall 33 and the sidewall 23 of the vessel 20. The
distribution chamber 50 is defined by the interior base plate 32
and the horizontal dividing plate 25.
The annular encircling cavity 40 is further divided by a
cylindrical baffle 35 into an inner annular portion 41 and an outer
annular portion 42. The top 36 of the baffle 35 is spaced from the
top 21 of the vessel 20 so as to place the top 43 of the inner
portion 41 of the annular encircling cavity 40 in fluid
communication with the top 44 of the outer portion 42 of the
annular encircling cavity 40. The bottom 37 of the baffle 35 is
mounted to the horizontal dividing plate 25 so as to prevent fluid
flow directly from the distribution chamber 50 to the outer portion
42 of the annular encircling cavity 40. Such a configuration
provides that pressurized heat exchange fluid 200 directed into the
distribution chamber 50 will flow up the inner portion 41 of the
annular encircling cavity 40 where it is operable for
adding/removing heat from a detergent composition 300 retained
within the casting chamber 30, and then down the outer portion 42
of the annular encircling cavity 40 and into the reservoir 60.
Perforations (unnumbered) are provided through that peripheral
portion of the horizontal dividing plate 25 in communication with
the outer portion 42 of the annular encircling cavity 40 so as to
provide fluid communication from the outer portion 42 of the
annular encircling cavity 40 to the reservoir 60.
A plurality of heat exchange tubes 70 extend longitudinally into
the casting chamber 30 from the interior base plate 32. The heat
exchange tubes 70 include concentric inner 71 and outer 72 pipes.
The top 74 of the outer pipe 72 is closed to prevent the
introduction of heat exchange fluid 200 into the casting chamber 30
and prevent the introduction of molten detergent composition 300m
into the heat exchange tubes 70. The top 73 of the inner pipe 71 is
open and spaced from the enclosed top 74 of the outer pipe 72 so as
to place the top (unnumbered) of the annular cavity 82 defined
between the inner 71 and outer 72 pipes in fluid communication with
the top (unnumbered) of the bore 81 extending through the inner
pipe 71. The bottom 75 of the inner pipe 71 extends through the
horizontal dividing plate 25 such that the bore 81 of the inner
pipe 71 is placed in direct fluid communication with the reservoir
60. The bottom 76 of the outer pipe 72 is secured to the interior
base plate 32 such that the annular cavity 82 is in direct fluid
communication with the distribution chamber 50. As with the annular
encircling cavity 40, such a configuration provides that
pressurized heat exchange fluid 200 directed into the distribution
chamber 50 will flow up the annular cavity 82 of each heat exchange
tube 70 where it is operable for adding/removing heat from a
detergent composition 300 retained within the casting chamber 30,
and then down the bore 81 of the inner pipe 71 and into the
reservoir 60.
The height of the baffle 35 and the inner pipes 71 must be
substantially the same so that heat exchange fluid 200 will flow
under the force of gravity into both the outer annular portion 42
of the annular encircling cavity 40 and the bore 81 of the inner
pipe 71 without favoring a particular flow path.
A central orifice 26 through the horizontal dividing plate 25 is
longitudinally aligned with a central orifice 34 through the
interior base plate 32 for accepting passage of a first end 91 of a
longitudinally extending central shaft 90. A collar 27 connects the
horizontal dividing plate 25 and the interior base plate 32 about
the circumferences of the respective central orifices 26,34 for
preventing fluid flow between the casting chamber 30 and the
distribution chamber 50. A receptacle 29 is mounted to the
horizontal dividing plate 25 immediately under the central orifice
26 in the horizontal dividing plate 25 for retaining the first end
91 of the central shaft 90 and preventing fluid flow between the
casting chamber 30 and the reservoir 60. An O-ring 28 is provided
within the collar 27 for sealingly contacting the central shaft 90
and reducing the flow of molten detergent composition 300m from the
casting chamber 30 into the receptacle 29. The central shaft 90 is
intended to be removed along with the solid cast block of detergent
composition 300s for facilitating the handling, transportation and
dispensing thereof. The central 90 would then be returned for reuse
in casting another block of detergent composition 300s.
A heat exchange system 100 is in fluid communication with the
distribution chamber 50 and reservoir 60 for selectively
circulating a heat exchange fluid 200 from the reservoir 60 through
a heating unit 120 or a refrigeration unit 130 and into the
distribution chamber 50. The distribution chamber 50, reservoir 60,
heating unit 120, and refrigeration unit 130 are interconnected by
a series of conduits and valves. A first conduit 141 provides fluid
communication between the outlet orifice 61 in the reservoir 60 and
the downstream port of a pump 110. A second conduit 142 provides
fluid communication between the upstream port of the pump 110 and
the refrigeration unit 130. A third conduit 143 branches from the
second conduit 142 at junction 151 for providing fluid
communication between the upstream port of the pump 110 and the
heating unit 120. A fourth conduit 144 provides fluid communication
between the heating unit 120 and an inlet orifice 55 in the
distribution chamber 50. A fifth conduit 145 branches from the
fourth conduit 144 at junction 152 for providing fluid
communication between the refrigeration unit 130 and the
distribution chamber 50. First 161 and second 162 valves are
located in the fourth 144 and fifth 145 conduits for permitting
selective circulation through the heating 120 and refrigeration 130
units.
OPERATION
An oversized solid block of detergent composition 300s may be
quickly and efficiently cast within the mold 10 depicted in FIGS.
1-3 by (i) pouring a sufficient quantity of molten detergent
composition 300m into the casting chamber 30, (ii) closing first
valve 161 and opening second valve 162 so as to direct the flow of
heat exchange fluid 200 through the refrigeration unit 130, (iii)
initiating operation of pump 110 to circulate heat exchange fluid
200 through the heat exchange system 100 and mold 10, (iv)
initiating operation of the refrigeration unit 130 to cool the heat
exchange fluid 200 passing therethrough, and (v) continuing to
circulate and cool the heat exchange fluid 200 until the cast
molten detergent composition 300m has solidified through
substantially the entire cross-sectional area thereof.
The solidified cast block of detergent composition 300s may be
removed from the casting chamber 30 by (i) continuing operation of
circulation pump 110, (ii) opening first valve 161 and closing
second valve 162 so as to redirect the flow of heat exchange fluid
200 from the refrigeration unit 130 to the heating unit 120, (iii)
initiating operation of the heating unit 120 to heat the heat
exchange fluid 200 passing therethrough, (iv) continuing to
circulate and heat the heat exchange fluid 200 until that layer of
the solidified cast block of detergent composition 300s in direct
contact with the casting chamber sidewall 33, casting chamber base
32, and heat exchange tubes 70 is liquefied, and then (v) pulling
the solid cast block of detergent composition 300s out of the
casting chamber 30 through the open top 21 of the vessel 20 using
the central shaft 90.
The heat exchange fluid 200 is stored within reservoir 60 and
pumped by pump 110 through the heat exchange system 100 and mold 10
for heating/cooling the detergent composition 300 within the
casting chamber 30. Specifically, the heat exchange fluid 200 is
pumped from the reservoir 60 through (i) the first length of
conduit 141, (ii) alternatively through the refrigeration sequence
of third length of conduit 143, refrigeration unit 130, and fourth
length of conduit 144, or the heating sequence of second length of
conduit 142, heating unit 120, and fifth length of conduit 145,
(iii) into the distribution chamber 50, (iv) simultaneously up the
outer annular cavities 82 in the heat exchange tubes 70 between the
inner 71 and outer 72 pipes, and the inner portion 41 of the
annular encircling cavity 40 between the sidewall 33 of the casting
chamber 30 and the baffle 35, (v) simultaneously down the bore 81
of the inner pipes 71 in the heat exchange tubes 70, and the outer
portion 42 of the annular encircling cavity 40 between the baffle
34 and the sidewall 23 of the vessel 20, and (vi) back into the
storage reservoir 60.
Cast Block of Detergent Composition
Nomenclature
90 central shaft
91 first end of central shaft
92 second end of central shaft
300 detergent composition
300s solid cast block of detergent composition
305 longitudinal circular channels
Construction
Referring to FIG. 5, the oversized solid cast block of detergent
composition 300s forms a right circular cylinder with a plurality
of longitudinal circular channels 305 created by the tubular heat
exchangers 70 extending through the solid cast block of detergent
composition 300s. The longitudinal circular channels 305 should
extend completely through the solid cast block of detergent
composition 300s to provide uniform dissolution of the detergent
composition 300 in a spray-type dispenser. Failure to extend the
longitudinal circular channels 305 completely through the solid
cast block of detergent composition 300s would result in the
presence of more detergent composition 300 at that end of the block
of detergent composition 300s which does not have longitudinal
circular channels 305 extending therethrough. This presence of
additional detergent composition 300 at one end would result in
nonuniform dissolution of the solid cast block of detergent
composition 300s across the length of the block of detergent
composition 300s and create the potential for difficulties to be
encountered in dispensing of the entire block of detergent
composition 300s from the central shaft 90.
The central shaft 90 remains attached to the solid cast block of
detergent composition 300s with a portion of each end 91,92
extending beyond the solid cast block of detergent composition 300s
for facilitating handling, transportation and dispensing of the
solid cast block of detergent composition 300s.
The constitution of the detergent/rinse aid composition is
unrestricted other than the basic requirements that the composition
be castable in molten form and function as a detergent or rinse aid
composition. Many such detergent and rinse aid composition
formulations are known including those described in Re. U.S. Pat.
No. 32,763, Re. U.S. Pat. No. 32,818, U.S. Pat. Nos. 4,595,520,
4,624,713 and 4,680,134 assigned to Ecolab, Inc of St. Paul,
Minn.
Dispenser
Nomenclature
500 spray-type dispenser
510 housing
510c dispensing chamber
512 bottom of housing
513 right side of housing
513t top edge of right side of housing
514 left side of housing
514t top edge of left side of housing
515 front of housing
517 semicircular notches in sides of housing
518 outlet orifice through bottom of housing
520 cover
523 right side of cover
523b bottom edge of right side of cover
524 left side of cover
524b bottom edge of left side of cover
527 semicircular notches in sides of cover
530 spray nozzle
540 rotational drive assembly
541 motor
542 first gear/drive gear
543 second gear/annular gear
544 chain
550 bushings
600 submersion-type dispenser
610 housing
610c dispensing chamber
612 bottom of housing
613 right side of housing
613t top edge of right side of housing
614 left side of housing
614t top edge of left side of housing
615 front of housing
617 semicircular notches in sides of housing
618 outlet pipe
620 cover
623 right side of cover
623b bottom edge of right side of cover
624 left side of cover
624b bottom edge of left side of cover
627 semicircular notches in sides of cover
630 inlet pipe
640 rotational drive assembly
641 motor
642 first gear/drive gear
643 second gear/annular gear
644 chain
650 bushings
660 level sensor
671 inlet valve
672 outlet valve
Construction
The solid cast block of detergent composition 300s may be dispensed
using any number of various types of dispensers including
submersion-type and spray-type dispensers. Briefly, the solid cast
block of detergent composition 300s may be dispensed by either (i)
submerging all or a portion of the solid cast block of detergent
composition 300s in water to dissolve a portion of the detergent
composition 300 and then directing the concentrated detergent
solution to a point of use, or (ii) spraying an exposed surface of
the solid cast block of detergent composition 300s with water and
then immediately directing the concentrated detergent solution to
either a storage tank or straight to a point of use.
The solid cast block of detergent composition 300s manufactured in
accordance with the process of this invention has all surfaces
exposed so as to provide a considerable contactable surface area
and thereby permit quick and efficient dissolution and dispensing
of the detergent composition.
Spray-Type
The solid cast block of detergent composition 300s may be
conveniently dispensed using the spray-type dispenser 500 depicted
in FIGS. 6 and 7. The basic function and design of spray-type
dispensers is well known as indicated by the disclosure of U.S.
Pat. Nos. 4,426,362, 4,571,327, 4,687,121, 4,690,305 and
4,826,661.
The spray-type dispenser 500 depicted in FIGS. 6 and 7 includes a
housing 510 defining a dispensing chamber 510c for retaining an
oversized solid cast block of detergent composition 300s. A cover
520 is hingedly connected to the housing 510 to permit complete
enclosure of the solid cast block of detergent composition 300s
during dispensing while providing access to the dispensing chamber
510c for loading of solid cast blocks of detergent composition
300s. The top 513t of the right side 513 and top 514t of the left
side 514 of the housing 510 include laterally aligned semicircular
notches 517 for retentatively accepting bushings 550 which have
been placed onto the exposed ends 91,92 of the central shaft 90 on
a solid cast block of detergent composition 300s. The bottom 523b
of the right side 523 and bottom 524b of the left side 524 of the
cover 511 include semicircular notches 527 which coincide with the
notches 517 in the right 513 and left 514 sides of the housing 510
for providing a complete encircling of the bushings 550 and
permitting the cover 511 to close completely while the ends 91,92
of the central shaft 90 on a solid cast block of detergent
composition 300s retained within the dispensing chamber 510c extend
from the sides 513,514 of the housing 510.
A spray nozzle 530 extends through the front 515 of the housing 510
for providing a spray of a dissolving solvent against the forward
facing surface of the solid cast block of detergent composition
300s. The spray dissolves a portion of the detergent composition
300 and forms a concentrated detergent solution which is directed
by the sloped bottom 512 of the housing 510 to an outlet orifice
518 from where it may be directed as desired.
Because only the forward facing surface of the solid cast block of
detergent composition 300s is contacted and dissolved by the water
spray, the solid cast block of detergent composition 300s should be
rotated about the central shaft 90 to provide uniform dissolution.
A means for rotating the solid cast block of detergent composition
300s is mounted on the right side 513 of the housing 510. The
rotational drive assembly 540 includes a motor 541, a first gear
542 mounted onto the drive shaft (unnumbered) of the motor 541, a
second gear 543 fixedly attached to the first end 91 of the central
shaft 90, and a chain 544 interconnecting the first 542 and second
543 gears. The speed with which the solid cast block of detergent
composition 300s should be rotated depends upon several factors
such as the amount of detergent composition 300 required and the
dissolution rate of the detergent composition 300. Accordingly, the
rotational speed should be determined on a case by case basis by
simply monitoring the speed with which the detergent composition
300 is dissolved and rotating the block of detergent composition
300s to prevent excessive dissolution from any particular portion.
Any of a number of appropriate means may be employed to provide the
desired rotational rate including motor selection and use of a
suitable gear ratio as between the first 542 and second 543 gears.
In addition, the solid cast block of detergent composition 300s
need only be rotated when the solid cast block of detergent
composition 300s is being sprayed with water. Again, any of a
number of appropriate means may be employed to provide the desired
rotational timing including interconnection of the start/stop
buttons (not shown) which control operation of the valve (not
shown) regulating water flow to the spray nozzle 530 and operation
of the motor 541 effecting rotation of the solid cast block of
detergent composition 300s.
Submersion-Type
Alternatively, the solid cast block of detergent composition 300s
may be conveniently dispensed using the submersion-type dispenser
600 depicted in FIG. 8. The basic function and design of
submersion-type dispensers is well known as indicated by the
disclosure of U.S. Pat. Nos. 1,949,264, 2,370,609, 2,477,998,
2,604,386, and 3,273,586.
The structure of the submersion-type dispenser 600 depicted in FIG.
8 is similar to the structure of the spray-type dispenser 500 of
FIGS. 6 and 7 and includes a housing 610 defining a dispensing
chamber 610c for retaining an oversized solid cast block of
detergent composition 300s. A cover 620 is hingedly connected to
the housing 610 to permit complete enclosure of the solid cast
block of detergent composition 300s during dispensing while
providing access to the dispensing chamber 610c for loading of
solid cast blocks of detergent composition 300s. The top 613t of
the right side 613 and top 614t of the left side 614 of the housing
610 include laterally aligned semicircular notches 617 for
retentatively accepting bushings 650 which have been placed onto
the exposed ends 91,92 of the central shaft 90 on a solid cast
block of detergent composition 300s. The bottom 623b of the right
side 623 and bottom 624b of the left side 624 of the cover 611
include semicircular notches 627 which coincide with the
semicircular notches 617 in the right 613 and left 614 sides of the
housing 610 for providing a complete encircling of the bushings 650
and permitting the cover 611 to close completely while the ends
91,92 of the central shaft 90 on a solid cast block of detergent
composition 300s retained within the dispensing chamber 610c extend
from the sides 613,614 of the housing 610.
An inlet pipe 630, which is in fluid communication with a source of
pressurized water, extends through the front 615 of the housing 610
for filling the dispensing chamber 510c with sufficient water to
submerse the lower portion of the solid block of detergent
composition 300s and thereby form a concentrated detergent solution
by dissolving a portion of the detergent composition 300. The level
of water in the dispensing chamber 610c is controlled by a level
sensor 660 mounted on the inside of the front 615 of the housing
610 which controls opening and closing of a valve 671 in the inlet
pipe 639. The concentrated detergent solution may be directed from
the housing 610 as desired by opening and closing a valve 672 in
the outlet pipe 618 which extends from the bottom 612 of the
housing 610.
Because only the downward facing portion of the solid cast block of
detergent composition 300s is contacted and dissolved by the water,
the solid cast block of detergent composition 300s should be
rotated 180.degree. about the central shaft 90 between each
dispensing cycle to provide uniform dissolution. A means for
rotating the solid cast block of detergent composition 300s is
mounted on the right side 613 of the housing 610. The rotational
drive assembly 640 includes a motor 641, a first gear 642 mounted
onto the drive shaft (unnumbered) of the motor 641, a second gear
643 fixedly attached to the first end 91 of the central shaft 90,
and a chain 644 interconnecting the first 642 and second 643 gears.
The solid cast block of detergent composition 300s need only be
rotated between dispensing cycles after the concentrated detergent
solution has been directed from the dispenser 600 and the solid
cast block of detergent composition 300s is no longer
submerged.
Operation
Spray-Type
The solid cast block of detergent composition 300s may be dispensed
from the spray-type dispensing system 500 depicted in FIGS. 6 and 7
by (i) placing a bushing 520 onto each of the first 91 and second
92 exposed ends of the central shaft 90 on the solid cast block of
detergent composition 300s, (ii) securing an annular gear 543 onto
the first end 91 of the central shaft 90 such that rotation of the
annular gear 543 effects rotation of the central shaft 90, (iii)
positioning the solid cast block of detergent composition 300s
within the dispensing chamber 510c defined by the housing 510 with
the bushings 550 previously placed onto the ends 91,92 of the
central shaft 90 retained within the laterally aligned semicircular
notches 517 in the right 513 and left 514 sides of the housing 510,
(iv) closing the cover 520 to completely enclose the solid cast
block of detergent composition 300s within the dispensing chamber
510c and sandwich the bushings 550 between the cover 520 and the
housing 510 within orifices (unnumbered) defined by a combination
of the semicircular notches 517 and 527 in the right 513,523 and
left 514,524 sides of the housing 510 and cover 520, respectively,
(v) linking the annular gear 543 coupled to the central shaft 90 to
the drive gear 542 mounted upon the drive shaft (unnumbered) of the
motor 541 with chain 544, (vi) spraying the solid cast block of
detergent composition 300s with a dissolving solvent sprayed
through the spray nozzle 530 so as to dissolve a portion of the
solid cast block of detergent composition 300s and form a
concentrated detergent solution (not shown), (vii) rotating the
solid cast block of detergent composition 300s during spraying to
provide a uniform dissolution of the solid cast block of detergent
composition 300s across the entire surface area thereof, (viii)
collecting the concentrated detergent solution within the
dispensing chamber 510c defined by the housing 510, and (ix)
directing the concentrated detergent solution from the dispensing
chamber 510c through the exit orifice 518 in the bottom 512 of the
housing 510 and on to a use location (not shown).
Submersion-Type
The solid cast block of detergent composition 300s may be dispensed
from the submersion-type dispensing system 600 depicted in FIGS. 8
and 9 by (i) placing a bushing 650 onto each of the first 91 and
second 92 exposed ends of the central shaft 90 on the solid cast
block of detergent composition 300s, (ii) securing an annular gear
643 onto the first end 91 of the central shaft 90 such that
rotation of the annular gear 643 effects rotation of the central
shaft 90, (iii) positioning the solid cast block of detergent
composition 300s within the dispensing chamber 610c defined by the
housing 610 with the bushings 650 previously placed onto the ends
91,92 of the central shaft 90 retained within the laterally aligned
semicircular notches 617 in the right 613 and left 614 sides of the
housing 610, (iv) closing the cover 620 to completely enclose the
solid cast block of detergent composition 300s within the
dispensing chamber 610c and sandwich the bushings 650 between the
cover 620 and the housing 610 within orifices (unnumbered) defined
by a combination of the semicircular notches 617 and 627 in the
right 613,623 and left 614,624 sides of the housing 610 and cover
620, respectively, (v) linking the annular gear 643 coupled to the
central shaft 90 to the drive gear 642 mounted upon the drive shaft
(unnumbered) of the motor 641 with chain 644, (vi) opening the
valve 671 in the inlet pipe 630 to permit fluid flow into the
dispensing chamber 610c from a source of pressurized fluid (not
shown) through the inlet pipe 630, (vii) closing the valve 671 in
the inlet pipe 630 to prevent fluid flow into the dispensing
chamber 610c from the pressurized source of fluid when a predefined
level of fluid is present in the dispensing chamber 610c, (viii)
permitting the fluid to contact the solid block of detergent
composition 300s so as to dissolve a portion of the solid cast
block of detergent composition 300s and form a concentrated
detergent solution (not shown), (ix) opening the valve 672 in the
outlet pipe 618 extending from the bottom 612 of the housing 610 so
as to direct the concentrated detergent solution from the
dispensing chamber 610c to a use location (not shown), and (ix)
rotating the solid cast block of detergent composition 300s
180.degree. in order to submerge the other half of the solid cast
block of detergent composition 300s during the next dispensing
cycle.
* * * * *